Norac UC4+ User manual

Miller Condor Monobeam Boom Installation
Manual
Spray Height Controller
Improving the competitiveness of Industry and Agriculture
throu
g
h Precision Measurement

Printed in Canada
Copyright 2005-08 by NORAC Systems International Inc.
Reorder P/N: UC4+BC+MC1-INST Rev B (Miller Condor Monobeam Boom)
NOTICE
NORAC Systems International Inc. reserves the right to improve products and their specifications without notice and without
the requirement to update products sold previously. Every effort has been made to ensure the accuracy of the information
contained in this manual. The technical information in this manual was reviewed at the time of approval for publication.

TABLE OF CONTENTS
1INTRODUCTION ................................................................................................................................. 1
2GENERAL SYSTEM DESCRIPTION .................................................................................................. 2
3PARTS LISTS......................................................................................................................................... 3
4INSTALLATION PROCEDURE.......................................................................................................... 7
4.1EXISTING SYSTEM CHECK ............................................................................................................... 7
4.2BOOM SPEED TEST ......................................................................................................................... 7
4.3WING SENSOR INSTALLATION ....................................................................................................... 9
4.4MAIN LIFT SENSOR INSTALLATION .............................................................................................. 12
4.5ROLL SENSOR INSTALLATION....................................................................................................... 13
4.5.1Boom Frame Roll Sensor Mounting......................................................................................................................................14
4.5.2Intermediate Frame Roll Sensor Mounting.........................................................................................................................15
4.5.3Reference Frame Roll Sensor .................................................................................................................................................17
Mounting ........................................................................................................................................................................................................17
4.6HYDRAULIC INSTALLATION.......................................................................................................... 18
4.6.1Valve Assembly...........................................................................................................................................................................18
4.6.2Valve Mounting ..........................................................................................................................................................................19
4.6.3Hydraulic Plumbing ...................................................................................................................................................................19
4.7ELECTRICAL INSTALLATION ......................................................................................................... 20
4.8COMPLETING THE INSTALLATION ................................................................................................ 24
5ELECTRICAL REFERENCE – CABLE DRAWINGS....................................................................... 25
5.1ITEM C02: 44668 –SENSOR BRANCH CABLE ............................................................................... 25
5.2ITEM C02B: 44664 –CABLE UC4 CAN NODE DUAL.................................................................. 25
5.3ITEM C03: 44656D –CABLE VALVE VARIABLE RATE DT ............................................................ 26
5.4ITEM C05: 44674 –CABLE UC3 SENSOR ROLL BIAS ................................................................... 26
5.5ITEM C10: 44650-39 –POWER CABLE GENERIC SELF-PROPELLED.............................................. 27
5.6ITEM C11: 44651-03 –EXTENSION CABLE VALVE GENERIC....................................................... 28
5.7ITEM C12: 44658-89 –CABLE INTERFACE UC4 BC GP (REVERSED POLARITY) ........................ 29
5.8ITEM C14: 44658-28 –CABLE INTERFACE UC4 BC POWER PIGTAIL.......................................... 30

1
1 INTRODUCTION
Congratulations on your purchase of the NORAC UC4+ Spray Height Controller. This system
is manufactured with top quality components and is engineered using the latest technology to
provide operating features and reliability unmatched for years to come.
When properly used the system can provide protection from sprayer boom damage, improve
sprayer efficiency, and ensure chemicals are applied correctly.
Please take the time to read this manual completely before attempting to install the system. A
thorough understanding of this manual will ensure that you receive the maximum benefit from
the system.
YOUR INPUT CAN HELP MAKE US BETTER! If you find issues or have
suggestions regarding the parts list or the installation procedure, please don’t
hesitate to contact us.

2
2 GENERAL SYSTEM DESCRIPTION
Figure 1 depicts the general system layout of the UC4+ Sprayer Boom Control system.
Figure 1 – System Components and General Location
NOTICE:
Every effort has been made to ensure the
accuracy of the information contained in
this manual. All parts supplied are selected
specially to fit the sprayer to facilitate a
complete installation. However, NORAC
cannot guarantee all parts fit as intended
due to the variations of the sprayer by the
manufacturer. Please read this manual
in its entirety before attempting
installation.
ATTENTION:
When installing the UC4+ Spray Height
Control system please be aware that at a
point in the installation your sprayer booms
will be inoperative until the installation is
complete. Any installation procedure
requiring boom movement will need
to be done first. Once the hydraulics
have been disconnected you must complete
the electrical installation before the booms
become operative.

3
3 PARTS LISTS
The parts that come with your UC4+ Sprayer Boom System are listed in Table 1. The item number on
the left side of this table references each part.
Please ensure that all parts in your kit are present before proceeding with your installation.
Table 1 – Sprayer Boom Control System Parts
Item Part Number Name Quantity
B05 44706-01 KIT CABLE TIE BLACK 10 PCS 21 IN 150 PCS 7.5 IN 1
B11 44743 MOUNTING BRACKET MAIN LIFT SENSOR UC4 PLUS 1
B13 44729 MOUNTING BRACKET NITRO UNIVERSAL SPRING BREAKAWAY 2
C02 44668 CABLE UC3 SENSOR BRANCH 1 AMP RECEPT 3 AMP PLUG BC 1
C02B 44664 CABLE UC4 CAN NODE DUAL 1
C03 44656D CABLE VALVE VARIABLE RATE DT 1
C05 44674 CABLE UC3 SENSOR ROLL BIAS 1
C10 44650-39 CABLE POWER GENERIC SELF-PROPELLED 1
C11 44651-03 CABLE EXTENSION VALVE GENERIC 1
C12 44658-89 CABLE INTERFACE UC4 BC C12 GP (REVERSED POLARITY) 1
C14 44658-28 CABLE INTERFACE UC4 BC C14 POWER PIGTAIL 1
E01 4461BC+ UC4 PLUS BOOM CONTROL PANEL 1
E02 44631 UC4 ULTRASOUND SENSOR 3
E03 45000* UC4 PLUS ROLL SENSOR W TEMPERATURE PROBE VER. 2 1
E04 45001* UC4 PLUS ROLL SENSOR VER. 2 2
H01 44863-51 HOSE ASSEMBLY 122R2-06 31IN L 6FORX 8FORX 2
H10 44865-59 HYDRAULICS FITTING KIT - MC01 & MC02 1
M01 446BC+MAN7 OPERATOR MANUAL UC4+ SPRAY HEIGHT CONTROL 1
M10 UC4+BC+MC1-INST MANUAL INSTALLATION UC4+ MILLER CONDOR MONOBEAM BOOM 1
V01 44963D VALVE BLOCK ASSEMBLY 2 STATION CC/LS PROP DT 4 BOLT 1
* For systems purchased BEFORE October 1, 2011, the roll sensor part numbers are 44641 and 44642.

4
Table 2 - 44865-59 - Hydraulics Fittings Kit Detail
Item Part Number Name Quantity
Picture
F01 106314 MALE ADAPTER - 8MB 8MOR 2
F02 104590 90 DEGREE ADAPTER - 6MOR 6FORX90 4
F03 44917 MALE TO MALE ADAPTER - 6MB 6MOR 4
F04 104885 TEE ADAPTER - 8FORXR 8MORT 2
F05 104369 PLUG - 6MBP 2
F06 104884 MALE TO FEMALE ADAPTER - 6MOR 8FORX 2
F07 106156 MALE TO FEMALE ADAPTER - 8MOR 6FOR 2
F08 105184 .018" INLINE ORIFICE - O-RING GROOVE ON FACE 2
F09 104592 O-RING HYD 3/8 IN FLAT FACE 2
F10 44928 ORIFICE INSERT .047 IN ONE WAY 2
F11 105151 MALE TO MALE ADAPTER - 6MB 8MOR 2
F12 101827 PLUG - 8MBP 2
6 M B - 6 M OR X 90
SIZE IN
1/16TH'S
GENDER: MALE
OR FEMALE
90° ANGLE
SWIVEL
TYPE
GENDER
SIZE
TYPE:
B - ORB
J - JIC
OR - FLAT
FACE
P - PIPE
Fitting Name
Example:

5
The parts that come with your UC4+ System are shown below in their general installation
configuration.
Figure 2 – UC4+ Spray Height Control system Components

6
Figure 3 – Hydraulic Plumbing Schematic
NOTE: Fitting F04 is not used for this install.
The use of dielectric grease is not recommended on any NORAC electrical connections.
To ensure all stainless steel hardware does not gall or seize apply a light coating of the
supplied Permatex Anti-seize grease to all threaded parts upon installation. Permatex
Anti-seize lubricant is preferred, but other similar anti-seize products may be used.

7
4 INSTALLATION PROCEDURE
4.1 EXISTING SYSTEM CHECK
It is necessary to check the existing
system’s functionality before installing the
UC4+ Spray Height Control system.
1. Drive your sprayer onto a flat piece of
land, with unobstructed boom
movement (e.g. no power lines).
2. Test that all boom functions operate
correctly. As you test each function
check it off in Table 3.
It is necessary to test the boom
functions in all directions
Table 3 – Hydraulic System Function
Check Sheet
BOOM FOLD IN FOLD OUT UP DOWN
LEFT
MAIN
RIGHT
ROLL* N/
A
N/
A
*Some sprayers may not have this function.
4.2 BOOM SPEED TEST
IMPORTANT:
Raise/lower all boom sections several
times to warm up the hydraulic
system. Grease all moving parts for
consistent results.
1. Lower each boom and main section as
close to the ground as possible.
2. Set your sprayer at field working RPM
on the throttle and mark this value in
Table 4.
You will need a stopwatch or a
watch that displays “seconds” for
the next step.
3. Raise the LEFT boom from its extreme
LOW position to the very TOP of its
travel. Record the time this takes in
Table 4,“Trial #1” for “Left UP”.
4. Lower the LEFT boom from its extreme
HIGH position to the BOTTOM of its
travel. Record this time in Table 4,
Trial #1 for “Left DOWN”.
Be careful when lowering the
booms so they don’t hit the
ground.
5. Similarly, record two more time trials
(Trial #2 & #3) for the LEFT boom and
record in Table 4.
6. Repeat Steps 1through 5for the
RIGHT, MAIN and ROLL functions.
Your sprayer may not have a roll
feature.
7. Average the three trials recorded for
each boom movement and record this
calculation in the “Average Time” slot in
Table 4.
8. These “Average Times” now represent
how quickly your system can react to
manual control. In Section 4.8, this
procedure is repeated with the UC4+
Spray Height Control system installed
for comparison and troubleshooting
purposes.

8
Table 4 – Boom Test Record (WITHOUT UC4+ Spray Height Control system)
Working RPM:
Boom Trial #1
[Sec]
Trial #2
[Sec]
Trial #3
[Sec]
A
vg Time
[Sec]
Left UP
Left DOWN
Right UP
Right Down
Main UP
Main DOWN
Roll CW
Roll CCW
Table 5 – Boom Test Record (WITH UC4+ Spray Height Control system)
Working RPM:
Boom Tria
l
#
1
[Sec]
Trial #2
[Sec]
Trial #3
[Sec]
A
vg Time
[Sec]
Left UP
Left DOWN
Right UP
Right Down
Main UP
Main DOWN
Roll CW
Roll CCW

9
4.3 WING SENSOR INSTALLATION
1. Assemble the Breakaway Sensor
Mounting Brackets (B11) as show in
Figure 4.
Figure 4 – Breakaway Sensor Bracket
Exploded View
To assemble the breakaway sensor
bracket:
a) Assemble the bolt and nut into the
collar.
b) Grease the bottom edge of the
collar and the angled tube of the
base.
c) Place the collar onto the angled tube
of the mounting base.
d) Install the spring between the collar
and the upper ring of the base.
e) Insert tube through assembly and
tighten the collar
2. Mount the sensor bracket onto the
boom.
If possible, mount the sensor
brackets while the booms are in
their folded position to ensure
that they will not interfere with
anything when the boom is folded
for transport.
Mounting the sensor bracket to
the break-away section of the
boom may cause the boom to
drop suddenly as a break-away
occurs. This will occur on break-
away sections which lift as they
break away.
For optimal boom tip protection,
it is recommended that the
sensor be mounted within
approximately two feet (60cm) of
the boom tip.
Figure 5 - Acceptable Mounting
Please refer to the UC4+ Spray Height
Control system warranty at the end of
the UC4+ Spray Height Control
Operator’s Manual (M01) for
implications.
3. Mount the NORAC UC4+ ultrasonic
sensor (E02) into the sensor brackets.
The sensors should be oriented forward
(ahead) of the boom (Figure 5 and
Figure 7).
When installing the UC4+
sensors (E02), start with the
smallest serial number on the left
hand side proceeding to the
largest serial number on the right
hand side (Figure 8).
FRONT

10
4. Sensor cables should run through the
mounting bracket tube and then behind
the member the bracket is mounted
onto. Cable-tie the connector in place.
The cable must not be allowed to hang
below the boom (Figure 6).
Figure 6 - Sensor Cable Routing
Avoid mounting sensors in
locations where they may read
from parts of the boom.
General mounting rules for UC4+
ultrasonic wing sensors:
a) In its lowest position, the sensor mouth
must be 9 inches or more from the
ground.
b) The bottom of the sensor must be at
least 9 inches in front of the spray
nozzles.
c) The bottom of the sensor must be at
least 9 inches above the spray nozzles.
d) Ensure that there are no obstructions
within a 12-inch diameter circle
projected directly below the center of
the sensor.
e) The sensor should be approximately
vertical at normal operating heights.
Figure 7 – Sensor Mounting
Guidelines
A
B
B
D
C
Ultrasonic
Acoustic Cone

11
Apply a light coating of the supplied Permatex Anti-seize grease to all threaded
parts upon installation.
Figure 8 – Sensor Serial Number Installation Location
3 SENSOR SYSTEM
5 SENSOR SYSTEM

12
4.4 MAIN LIFT SENSOR INSTALLATION
1. Assemble the main lift sensor bracket
(B11) as shown in Figure 9.
Figure 9 – Main Lift Sensor Bracket
2. The bracket can then be mounted to
the lowest frame member on the center
section of the sprayer. The bracket
should be mounted so the sensor
mounting collar is in approximately the
center of the sprayer and ahead of the
boom (Figure 10 and Figure 11).
The sensor mounting collar must
not be behind the sprayer’s
wheel.
The General Mounting Rules for
UC4+ Ultrasonic Sensors, from
the previous section, must be
followed.
Figure 10 – Main Lift Sensor Bracket
Mounting Position
3. Mount the sensor onto the sensor
mounting collar (Figure 10).
Figure 11 – Main Lift Sensor Mounted
in the Correct Location
Bracket Tube
Sensor
Mounting Tab
Sensor Mounting
Colla
r
Bracket Base

13
4.5 ROLL SENSOR INSTALLATION
Mount the roll sensors to the included roll
sensor brackets using the machine screws
and nylon lock nuts, as illustrated in Figure
12.
The roll sensors must be
mounted tightly to the brackets.
Figure 12 – Mounting the Roll Sensor
to the Roll Sensor Mounting Bracket
When mounting the roll sensors, use the
following guidelines and refer to Figure 13.
a) The intermediate frame roll sensor
must have the lowest serial number and
the chassis roll sensor must have the
highest serial number.
b) The smaller the distance between Aand
Bin Figure 13, the better the
performance will be.
c) Ensure the roll sensors are sitting
relatively level when the sprayer chassis
and boom are level.
d) All roll sensors must be mounted with
the circular AMP connector facing
towards the Right-Hand Wing (when
looking from the rear of the sprayer).
Figure 13 – General Roll Sensor Mounting Location on a Trapeze Style Boom
Connectors towards
Right-hand Wing 

14
4.5.1 Boom Frame Roll Sensor
Mounting
1. Use the supplied hardware to mount
the boom frame roll sensor (E04) as
shown in Figure 14 and Figure 17.
When mounting the boom frame roll
sensor follow these guidelines:
a) To prevent bending the bracket,
ensure bolts are placed as close
together as possible (minimize Cin
Figure 14).
b) Be sure to use the roll sensor
without the temperature probe
(E04).
c) When the boom is centered (not
rolled over) the roll sensor should be
level with respect to the sprayer
chassis.
d) It is best to mount the roll sensor to
the left hand trapeze link (when
looking from the rear of the sprayer).
e) The roll sensor AMP (circular)
connector MUST exit towards
the right hand wing (when looking
from the rear of the sprayer).
Figure 14 – Boom Frame Roll Sensor
Mounted to a Trapeze Link
2. Cable-tie the sensor connector to the
frame with enough slack to allow the
link to rotate.
Make sure the bracket does not
collide with any parts of the
sprayer when the boom rotates.
Also ensure there is enough slack
to allow the roll sensor to rotate.

15
4.5.2 Intermediate Frame Roll Sensor Mounting
The intermediate frame roll
sensor has the temperature
probe on it.
1. It is often best to cable tie the
intermediate frame roll sensor in place.
When mounting the intermediate frame
roll sensor follow the guidelines and
refer to Figure 15 and Figure 17.
The intermediate frame roll
sensor must be mounted on a
portion of the sprayer that does
not pivot and is as close to the
boom frame roll sensor as
possible (Figure 13).
a) Make sure you are using the roll
sensor with the temperature probe
(E03).
b) Ensure the roll sensor is level with
respect to the chassis.
c) The AMP (circular) connector MUST
exit towards the right hand wing
(when looking from the rear of the
sprayer).
d) Make sure the temperature probe is
able to reach the side of the valve
block.
Figure 15 – Intermediate Roll Sensor
Mounting
2. Fasten the temperature probe to the
UC4+ valve block, using the supplied
3/8”x1/2” bolt as shown in Figure 16.
3. Cable-tie the temperature probe cable
and AMP (circular) connector securely
to a frame member.
Check that the roll sensors and
cables will not interfere with, or
come into contact with any parts
of the sprayer.
Figure 16 – Temperature Probe
Attached to the UC4+ Valve Block

16
Figure 17 – Intermediate and Boom Frame Roll Sensor Mounting
Boom Frame
Roll Sensor
Inte
r
mediate Frame
Roll Senso
r

17
4.5.3 Reference Frame Roll Sensor
Mounting
The reference frame roll sensor
should be the highest serial
number.
1. The reference frame (chassis) roll sensor
mounts on the chassis of the sprayer as
shown in Figure 18. The AMP
(circular) connector MUST exit
towards the right hand wing.
2. Ensure the sensor is mounted adequately
and that the cable provides enough slack.
Figure 18 – Reference Frame Roll Sensor Mounting